Technology Trends in Process Automation

With increasing pressure to operate efficiently and meet global sustainability goals, the process industry is turning to technology for answers.

Process industries like oil & gas, fertilisers, pharmaceuticals, chemicals and petrochemicals cater to a large and diverse sector that manufactures a wide range of products, including agricultural produce, pharmaceutical excipients, plastics and polymers, surface finishes, and a host of other products. Along with a significant amount of research and development, this industry produces chemicals from raw material such as fossil fuels and other natural resources using various techniques and advanced technologies. Global trends like sustainability and environmental concerns, and digitalisation and autonomous systems are also impacting the sector. So what exactly is the current state of the process industry in terms of growth, innovation, and regulatory challenges?

“Today’s process industry is witnessing unprecedented momentum, propelled by rising domestic demand, global supply chain realignments, and transformative government initiatives such as Production-Linked Incentives (PLI), Atmanirbhar Bharat, Make in India, and Gati Shakti,” says Dr Bijal Sanghvi, Managing Director, Axis Solutions Limited. “With the Indian chemical industry projected to reach USD 300 billion by 2025, the pharmaceutical sector expected to expand to USD 130 billion by 2030, and the oil & gas segment poised to attract over USD 100 billion in investment to meet the surging energy needs of a fast-growing economy, the sector is entering a phase of accelerated growth and strategic importance. Yet, this rapid expansion also brings significant challenges, including stricter emission norms, enhanced workplace safety requirements, the need for operational resilience, and compliance with both national and international regulations,” he adds. To stay competitive, industries must adopt integrated automation, advanced instrumentation, and robust analytical systems that modernise infrastructure, optimise efficiency, ensure environmental responsibility, and support digital transformation. By embracing innovation, sustainability, and data-driven decision-making, the process industry can not only meet regulatory benchmarks but also drive smarter, safer, and more sustainable growth – paving the way for long-term global competitiveness and resilience.

Mark Sen Gupta, Director of Research, ARC Advisory Group, USA, believes that the process industry is experiencing cautious growth, driven by digital transformation initiatives, improvements in automation, and more focused AI adoption. Sectors like pharmaceuticals and biotech are leading with investment in platform technologies, personalised therapies, and global expansion. Innovation is accelerating in areas such as predictive maintenance, modular automation, and integrated supply chains. However, legacy systems and fragmented data models continue to hinder operational performance. “Regulatory pressure is intensifying globally, especially around decarbonisation, safety standards, and sustainability. Governments are enforcing stricter emissions policies while offering incentives for low-carbon technologies. Meanwhile, the shortage of qualified safety professionals in most regions and perceived complexity of compliance are slowing progress. Despite these challenges, strategic integration of technology and regulatory alignment is helping future-ready companies stay competitive,” he says.

“The process industry, which encompasses oil & gas, chemicals, petrochemicals, fertilizers, and pharmaceutical sectors, is undergoing a profound transformation. Despite global economic and geopolitical instability, process industries continue to demonstrate resilience by reconfiguring supply chains, prioritising regional sourcing, and adopting technological advancement,” says Smitha Rao, Founder & Director, OjasQuest. “Process industries are now catching up fast in AI adoption, moving from pilot projects to full-scale implementation. Integrating AI with Legacy Systems, managing high complexity and safety-critical environments is posing many challenges that require a strong governance and migration plan in place. Especially for process safety related solutions, hybrid approach by blending AI-generated insights with expert validation enables organisations to progressively adopt AI-driven safety protocols with greater confidence and reliability,” she explains.

The process industry has long been a leader in adopting industrial automation to manage complex processes involving the flow of liquids and gases, driven as it is, by needs for quality, consistency, safety, and 24/7 operation, the industry. What role is digital transformation – technologies like AI, IIoT, and automation –  now playing in improving process efficiency and safety?

“Digital transformation is revolutionising the process industry in India, with technologies like Artificial Intelligence (AI), the Industrial Internet of Things (IIoT), and automation playing a pivotal role in enhancing both efficiency and safety. These technologies enable real-time monitoring, predictive analytics, and intelligent control systems that significantly reduce downtime, optimise resource utilisation, and improve decision-making across operations,” says Aradhaya Srivastava, Business Development – Process, WAGO India. According to him, AI-driven predictive maintenance is one of the most impactful innovations, allowing companies to anticipate equipment failures before they occur. “This not only minimises unplanned outages but also extends asset life and reduces maintenance costs. IIoT platforms, by connecting sensors and devices across the plant floor, provide granular visibility into process parameters such as temperature, pressure, and flow rates. This data is continuously analysed to ensure optimal performance and to detect anomalies that could lead to safety hazards,” he elaborates. Srivastava also believes automation, particularly through robotics and advanced control systems, is streamlining repetitive and hazardous tasks, thereby reducing human error and exposure to dangerous environments. For example, automated dosing systems in chemical plants ensure precise ingredient mixing, improving product quality and reducing risks of chemical mishandling. Similarly, AI-powered safety systems can monitor compliance with safety protocols, detect unsafe behaviours, and trigger alerts or shutdowns in case of emergencies.

“Today, digital transformation in process industries is slowly moving from experimentation to tangible impact, particularly in areas of efficiency, safety, and sustainability. While adoption is uneven, with many companies still spending less than 10% of their budgets on digital technologies, those that are scaling efforts are seeing measurable gains,” says Dinesh Thukaram, Chief Solutions Officer, Utthunga. He also believes digital systems are helping companies integrate legacy and new infrastructure, retain process knowledge as workforces shift, and prepare for sustainability targets. Technologies such as AI, IIoT, and automation are addressing long-standing challenges like unplanned downtime, energy inefficiencies, and operational safety. For instance, energy management and optimisation systems (such as those deployed by Utthunga) can lower consumption by 5-12%, and automated safety interlocks and monitoring can reduce safety incidents by 15-25%. IIoT-enabled monitoring also provides real-time diagnostics from instrumentation and valves, strengthening maintenance and safety performance in plants. “The challenge ahead is less about technology readiness and more about scaling and sustaining these solutions. Leaders in the sector are those moving beyond pilots into enterprise-wide deployment, creating new operating models where efficiency, safety, and sustainability are built into the fabric of daily operations,” he opines.

“Digital transformation through technologies like AI, IIoT and advanced automation is no longer aspirational, it has become foundational to the future of industry. These technologies are driving predictive maintenance, process optimisation, real-time monitoring, and data-driven decision-making, while simultaneously minimising human error, reducing energy consumption, improving resource efficiency, and preventing costly downtime,” says Dr Bijal Sanghvi. At the core of this transformation lies the Industry 4.0 framework, which seamlessly integrates machines, sensors, data, and systems to create end-to-end connectivity, unlock real-time intelligence, and generate actionable insights that enable higher levels of efficiency, reliability, and sustainability. By embracing these advancements, the process industry can achieve safer plant operations, smarter workflows, enhanced productivity, and greater adaptability to dynamic market demands. “Ultimately, the convergence of digital technologies and industrial processes is paving the way for intelligent, connected, and future-ready ecosystems that support not only operational excellence but also long-term resilience and sustainable growth in an ever-evolving global landscape,” says Dr Sanghvi.

Data is crucial in the process industry for optimising operations, reducing costs, improving product quality, enhancing safety, and enabling strategic decision-making through real-time insights and predictive capabilities. But how is the process industry leveraging data analytics or cloud technologies to enhance traceability, quality control, and decision-making?

According to Mark Sen Gupta, the process industries have increasingly leveraged data analytics and cloud technologies to enhance traceability, quality control, and decision making. Cloud-based technologies have enabled real-time data aggregation and sharing across operations, improving visibility and collaboration. Industrial DataOps frameworks now integrate IT and OT data streams, allowing predictive analytics and digital twins to support proactive maintenance and risk assessment. “Traceability has improved through version control and automated alerts embedded in data pipelines, ensuring data integrity and enabling rapid response to anomalies. Quality control benefits from AI-driven inspection systems and contextualised data, which can unify sensor, engineering, and operational data into dynamic digital twins,” he says. Decision-making is increasingly data-driven, supported by MES platforms and unified data fabrics that provide enterprise-wide access to structured, historical, and real-time data. These systems empower operators to make informed choices, optimise asset performance, and comply with evolving standards. “As digital transformation deepens, the synergy between cloud infrastructure, analytics, and industrial AI continues to redefine operational excellence in the process industry,” explains Sen Gupta.

For Smitha Rao, quality control can result in substantial operational cost and, in order to mitigate this, it requires a well-designed framework to implement cloud-based analytics for better quality control. “Choosing the right cloud based analytics solution provider based on the existing process in place, and training and managing the change with the current workforce, is the key. Adoption of these technologies helps in predictive maintenance, real-time quality monitoring, better inventory and supply chain management,” she says.

“Advanced data analytics, powered by AI and machine learning, is being used to monitor process parameters and detect deviations in real time. These insights enable proactive quality control by identifying root causes of defects and optimising process variables to maintain consistent product standards. Predictive analytics also supports better asset management by forecasting equipment failures and scheduling maintenance, thereby minimising downtime and improving operational efficiency,” says Aradhaya Srivastava. Moreover, cloud-enabled dashboards and analytics tools empower decision-makers with actionable insights. Plant managers and executives can access key performance indicators, energy usage, and production trends from anywhere, enabling faster and more informed decisions. “This agility is particularly valuable in responding to market fluctuations, supply chain disruptions, or compliance audits, he emphasises. As digital maturity increases, these tools will become even more critical in building resilient, efficient, and competitive industrial operations.

With increasing pressure on companies globally to comply with stringent environmental norms, what are the options for companies to reduce carbon emissions and meet ESG goals, and how do they influence operations and investment decisions in this industry?

“The pressure to meet carbon reduction and ESG targets is pushing companies to rethink how plants are designed, operated, and modernised. Maintaining competitiveness today requires companies to integrate ESG priorities into their core strategy, not just as a compliance exercise or a CSR activity, but as a driver of operational and financial performance,” says Dinesh Thukaram. By systematically reducing operating costs, enhancing energy efficiency, minimising waste, and rationalising material usage, organisations can lower their environmental footprint while strengthening profitability. “Crucially, the cost savings generated will form a self-reinforcing cycle, freeing up capital to fund further sustainability initiatives. This creates a virtuous loop that drives continuous improvement in both business performance and ESG outcomes,” he elaborates.

Dr Bijal Sanghvi too agrees that ESG considerations are increasingly shaping capital expenditure decisions, operational workflows, and technology investments across industries worldwide. With growing global emphasis on decarbonisation, energy efficiency, and climate-conscious production, businesses are under increasing pressure to adopt cleaner, more sustainable technologies and demonstrate measurable environmental and social impact. “Organisations are now seeking solutions such as continuous emission monitoring systems, energy-optimised infrastructure, and safety-compliant equipment that not only enhance operational efficiency but also support long-term sustainability goals. By integrating technologies that monitor emissions, optimise energy consumption, and ensure safe, compliant operations, industries can significantly reduce their carbon footprint, align with national and international environmental regulations, and strengthen their contribution to ESG targets. Beyond regulatory compliance, these initiatives also help businesses improve stakeholder trust, enhance operational resilience, and position themselves as leaders in sustainable industrial practices, paving the way for long-term competitiveness, social responsibility, and environmentally conscious growth.

There are various alternatives cited like biodegradable packaging (in packaging/food), green hydrogen (in oil & gas), or continuous manufacturing (in pharma). How viable are these from a commercial standpoint?

“Biodegradable packaging is gaining traction in food and consumer goods due to regulatory pressure and consumer demand. Innovations in bio-based plastics and digitised packaging processes are helping manufacturers meet sustainability goals while maintaining quality and traceability. However, cost and scalability remain challenges, especially in regions with limited recycling infrastructure,” says Mark Sen Gupta. Also Green Hydrogen is emerging as a viable decarbonisation tool in oil and gas, particularly for hard-to-abate sectors like steel and refining. Major investments – such as Air Liquide’s €400M electrolyzer project and Chevron’s stake in ACES Delta – signal growing confidence in its commercial potential. Yet, high production costs and limited infrastructure still hinder widespread adoption. “Continuous manufacturing in pharma is commercially promising, especially for mRNA and personalised therapies. It accelerates time-to-market, reduces waste, and supports digital twin integration for quality control. Regulatory alignment and upfront investment remain hurdles, but momentum is building across North America and Europe,” he points out.

Smitha Rao cites the example of Nandini Milk introducing India’s first biodegradable milk pouches. “However, at present these eco-friendly packaging increases the cost and, hence, are affordable only to big brands and suitable for premium and eco-conscious markets,” she says. Similarly, Green Hydrogen is seen as a game changer for decarbonising refining, upstream logistics, and high-temperature industrial processes. Companies like Reliance Industries, Shell, BP, TotalEnergies, and Saudi Aramco are actively investing in green hydrogen infrastructure. Here too, high costs of electrolyzers and renewable energy and infrastructure gaps in transport and storage are slowing the adoption across all the sectors. Regarding continuous manufacturing in pharma (PCM), since the pandemic, PCM has gained significant traction and is poised to become a mainstream complement to traditional batch production for both innovative and generic drugs. PCM enhances output, efficiency, and cost-effectiveness, while reducing environmental impact and reliance on foreign suppliers. In this connection, Smitha Rao draws attention to the launch of the Centre of Excellence in Flow Chemistry and Continuous Manufacturing to promote PCM adoption by the Indian government, in collaboration with Dr Reddy’s and Laurus Labs. “PCM adoption in India is commercially viable and expanding, supported by strong manufacturing capabilities, cost advantages, and proactive policy measures. With growing infrastructure and regulatory alignment, India is well-positioned to lead in PCM innovation globally,” she explains.

So what emerging trends or technologies are most likely to significantly shape the future of this industry over the next decade?

“Over the next decade, the process industry is set to undergo a profound transformation driven by a convergence of emerging technologies and evolving market demands. Among the most influential trends is the widespread adoption of AI and ML, which are revolutionising process optimisation, predictive maintenance, and quality control. These technologies enable real-time decision-making, reduce downtime, and enhance operational efficiency, with 93% of manufacturers already recognising AI as a key driver of growth,” says Aradhaya Srivastava. “Digital twins, as mentioned earlier, are also gaining traction, allowing companies to simulate, monitor, and optimise processes before implementing changes on the shop floor. This not only improves performance but also supports sustainability by minimising waste and resource consumption. Coupled with smart manufacturing and Industry 4.0 technologies, digital twins are making operations more adaptive and resilient to disruptions,” he adds.

Dinesh Thukaram concurs with this observation, and agrees the industry will be transformed by the integration of digital technologies, advanced materials, and process innovations. Artificial intelligence and predictive analytics will optimise operations in real time, while automation and continuous manufacturing approaches will drive efficiency and reduce waste. Advanced digital twin solutions, like Utthunga’s Integrated Digital Twin Engineering Solution, connect physical and digital worlds – integrating OT/IT data, industrial IoT, CAD models, and control systems – to simulate, optimise, and monitor operations before changes are applied on the shop floor. With role-based dashboards, 3D visualisations, AR/VR, and predictive insights, decision-makers across operations, engineering, and maintenance can act faster, reduce risk, and enhance safety. Innovations in energy management, such as electrification of processes and adoption of low-carbon fuels, will also play a central role in meeting sustainability targets. “While many organisations are experimenting with new technologies, the real differentiator lies in domain-led digital integration – where deep industry expertise is combined with digital innovation to ensure solutions are not just advanced, but also practical, interoperable, and impactful on the ground. By leveraging data-driven insights with integrated engineering approaches and domain-led execution, organisations can make smarter decisions, improve agility, and build operations that are resilient, adaptable, and prepared for the challenges of the future,” he concludes.

Note: The responses of various experts featured in this story are their personal views and not necessarily of the companies or organisations they represent. The full interviews are hosted online at https://www.iedcommunications.com/interviews)